Tonneau cover access panel

ABSTRACT

A tonneau cover access panel assembly connectable to a vehicle that eliminates the need for side rails to both locate and tension a tonneau cover. The assembly also reduces weight and complexity. The assembly incorporates a readily accessible rear latching system that reduces or eliminates interference with the tonneau cover during operation. The assembly also incorporates a tonneau cover tensioning system. The tension seals out environmental elements and holds the tonneau cover and locating bows in place. The assembly holds the tonneau in the closed tension state keeping the tonneau cover secured and tight until the cover is opened by an operator. The assembly is movable between a closed position and a fully open/stowable position and any intermediate positions. The assembly is also movable between at least a first open position and the deployed position for more limiting access to the cargo bed of the vehicle when desired.

CROSS REFERENCE TO RELATED APPLICATIONS

The instant application is a continuation of U.S. patent applicationSer. No. 16/271,437, filed Feb. 8, 2019, which is a continuation of U.S.patent application Ser. No. 15/487,037, filed Apr. 13, 2017, now U.S.Pat. No. 10,239,394, issued Mar. 26, 2019, which is acontinuation-in-part of U.S. patent application Ser. No. 15/342,761,filed on Nov. 3, 2016, now U.S. Pat. No. 10,363,801, issued Jul. 30,2019, which claims benefit of U.S. Provisional Application No.62/250,290, filed Nov. 3, 2015. The disclosures of the aboveapplications are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a pivotable bed cover closeout devicefor a cargo bed of a vehicle which is movable to desired positions.

BACKGROUND OF THE INVENTION

Removable or stowable soft tonneau covers for pickup vehicles are knownin the art. These tonneau covers provide a vehicle with access to thecargo bed when the cover is pulled/folded back or removed, or, providesprotection from the elements with the tonneau cover on/deployed. Suchtonneau covers are typically manually unlatched on both sides beforebeing moved into the desired positions.

Currently, tonneau covers have a rail that must be mounted down eachside of the pickup box to give the cover a place to attach and seal outthe elements. Typically, the rails are aluminum and/or the cover is afabric cover. These side rails also act as a locator, aligning thebows/top cover as it is installed and positioned and provide a way totension the top cover. Having to install these rails leads to additionalheight on the vehicle, cost, a non-cohesive look, and additionweight/complexity in the top.

There are other tonneau systems that are labeled as “low profile” tohelp fight the height and non-cohesive look. However, these covers stilluse an additional rail to mount the cover to the pickup bed and gainfabric tension so the design is no different than a “conventional”tonneau cover, it is just a different geometry.

Therefore, there remains a need for a system that eliminates the needfor side rails, that utilizes an add-on bracket and/or an integrated beddesign as an attachment method, eliminates the need of an additionalattachment to gain tonneau cover tension, and provides easy multipleposition accessibility into the cargo bed.

SUMMARY OF THE INVENTION

A tonneau cover assembly incorporating a cable-type system or any othertype of suitable system that tensions a top cover, providing tensionalong the side of the cover to seal the cover to a bedside of a vehicle.When cables are used, the cables running down either side of the coversolves many of the aforementioned issues. Using a cable running fore andaft on the pickup truck or sport utility (SUV) vehicle bedsideeliminates the need for the side rails to both locate and tension thetop cover. The cable tension works to seal out the elements and holdsthe tonneau cover and bows in place.

With a rear engagement feature according to an embodiment of the presentinvention, it is readily implementable both as an add on bracket or asan integrated feature in a pickup truck bed or SUV or adapted to anyother vehicle type. A rear latching system holds the tonneau in theclosed tension state keeping the tonneau secured and tight until thecover is opened by an operator.

Optionally, an integrated boot cover is also sewn into the top cover atthe front so that when the tonneau cover is rolled up in the stowedposition, the boot cover can wrap and protect the top cover.

Preferably, according to an embodiment of the present invention, pocketsare provided to hold the ends of center management bows to set theheight and eliminate aluminum rails and attachment features. When thetop cover is fabric or other flexible material these pockets, e.g., madeof acrylonitrile butadiene styrene (ABS) having predetermined suitablethickness, are preferably sewn to the underside surface of the cover.

The tonneau cover assembly is mounted at a predetermined location insealing engagement with a tailgate and is pivotable between at least aclosed position sealing off with the vehicle tailgate, and a partiallyopen position folded rearward to gain access into the cargo bed. When inthe partially open position the opening into the bed is limited toprovide the predetermined desired amount of accessibility to the bed,e.g., creates about a 6 inch opening for access. This has significantbenefits, including, security, ease of stowing and accessing items nearthe tailgate, eliminating the need to fully open the tailgate and/ormove the entire cover to access the bed, quicker access to the bed, andexpedient cargo holding, e.g., hauling longer items such as wood planksextending through the opening and into the cargo bed. Intermediate openposition(s) is/are also contemplated.

The tonneau cover assembly is also movable between the closed position,partially open position, and a fully open position for full access tothe cargo area, according to an embodiment of the present invention.Intermediate position(s) is/are also contemplated.

The tonneau cover assembly reduces weight and complexity, and eliminatesthe side rails when compared to current tonneau systems.

According to another embodiment of the present invention, at least onerelease lever of the rear latching system is mounted in a convenientlocation for easier access to pull the release lever generally towardthe operator for releasing the latching mechanism, when desired. Therelease lever location(s) reduces or eliminates interference with thecover to operate. The cable system runs fore and aft, and additionallyhas cable tensioning along the front of the system.

Using a cable running fore and aft on the pickup truck or sport utility(SUV) vehicle bedside eliminates the need for the side rails to bothlocate and tension the top cover. The cable tension works to seal outthe elements and holds the tonneau cover and bows in place.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a right hand perspective view of a tonneau cover assemblyaccording to the present invention, with the cover material omitted forclarity;

FIG. 2 is a partially exploded view of the tonneau cover assembly ofFIG. 1 shown from the left side, in accordance with the presentinvention;

FIG. 3 is an enlarged rear perspective view of a front attachmentassembly connected to a first bow and a first tension cable of FIG. 1,in accordance with the present invention;

FIG. 4 is an enlarged front perspective view of the front attachmentassembly connected to the first bow, in accordance with the presentinvention;

FIG. 5 is a partially exploded front view of the front attachmentassembly of FIGS. 3-4 and the first bow, in accordance with the presentinvention;

FIG. 6 is an enlarged view of a segment of a rear attachment assemblyfrom FIG. 1 including a rear attachment block connected to a releaselatch mechanism, in accordance with the present invention;

FIG. 7 is an exploded view of the rear attachment block and partialopening feature;

FIG. 8 is an enlarged rear perspective view of a portion of FIG. 1showing one end of each of a pair of cover management bows pockets;

FIG. 9 is a perspective view of a tonneau cover access panel assembly,shown in an exemplary environment of use with the cover material omittedfor clarity, according to an embodiment of the present invention;

FIG. 10 is a top plan view of the tonneau cover access panel assembly,according to the present invention;

FIG. 11 is a bottom plan view of the tonneau cover access panelassembly, according to the present invention;

FIG. 12 is a side elevation sectional view of the tonneau cover accesspanel assembly in a closed position, showing a spring loaded detent,according to the present invention;

FIG. 13 is a side elevation sectional view of the tonneau cover accesspanel assembly in a closed position, illustrating a latch mechanismhook, according to the present invention;

FIG. 14 is a side elevation sectional view of the tonneau cover accesspanel assembly in an open position, showing a spring loaded detent,according to the present invention;

FIG. 15 is a side elevation sectional view of the tonneau cover accesspanel assembly in an intermediate open position, showing a spring loadeddetent, according to the present invention;

FIG. 16 is a front perspective view of the tonneau cover access panelassembly, depicted in an environment of use adjacent a tailgate,according to the present invention;

FIG. 17 is a rear perspective view of the tonneau cover access panelassembly in a closed position, and shows a bow pocket, according to thepresent invention;

FIG. 18 is a rear isometric view of the tonneau cover access panelassembly in a closed position, according to the present invention;

FIG. 19 is bottom perspective view of a bow pocket connected to asection taken of the cover, according to the present invention;

FIG. 20 is a perspective view of an exemplary tonneau cover access panelassembly depicted in an environment of use on a vehicle, according to anembodiment of the present invention;

FIG. 21 is a perspective view of a tonneau cover assembly with the covermaterial omitted for clarity, depicted in an environment of use on avehicle, according to another embodiment of the present invention;

FIG. 22 is an enlarged perspective view of a rearward portion of theassembly of FIG. 21, according to the present invention;

FIG. 23 is a top plan view of the assembly of FIG. 22, according to thepresent invention;

FIG. 24 is a side elevation sectional view of a mounting bracketconnected to the vehicle and illustrating a latching mechanism of thetonneau cover access panel assembly in an unlatched position, accordingto the present invention;

FIG. 25 is a side elevation sectional view illustrating the latchingmechanism of FIG. 24 in a latched position, according to the presentinvention;

FIG. 26 is an enlarged right hand perspective view of a forward portionof the assembly depicted in FIG. 21, according to the present invention;

FIG. 27 is a front elevation view of a front portion of the assemblydepicted in FIG. 21, according to the present invention;

FIG. 28A is a perspective view of a bow pocket that is connectable tothe cover of the assembly, according to an embodiment of the presentinvention;

FIG. 28B is an exploded perspective view of the bow pocket connected toa bow, and a section taken of the cover that is connectable to the bowpocket, according to an embodiment of the present invention;

FIG. 29 is a partial exploded left hand perspective view depicting someof the connecting features of the rear attachment assembly, according tothe present invention;

FIG. 30 is a perspective view of the tonneau cover access panel assemblydepicted in an environment of use on a vehicle shown in a closedposition, according to an embodiment of the present invention;

FIG. 31 is a perspective view of the tonneau cover access panel assemblyin a first open position for partial access into the vehicle bed,according to the present invention;

FIG. 32 is a perspective view of the tonneau cover access panel assemblyof FIGS. 30-31 further opened, according to the present invention; and

FIG. 33 is a perspective view of the tonneau cover access panel assemblyin a fully open, stored position for full access into the vehicle bed,according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring to FIGS. 1-8 generally, there is provided a rear attachmentassembly (or “tonneau cover access panel assembly”) shown generally at16 illustrated with an exemplary tonneau cover assembly shown generallyat 10 that is a cable-type system. The tonneau cover assembly has acover 12, e.g., fabric material, soft or flexible material, vinyl or anyother suitable material and combinations thereof depending on theapplication. The tonneau cover assembly 10 also has a front attachmentassembly 14, and a at least one, preferably, a plurality of covermanagement bows 18. These cover management bows 18, most preferably, twobows, are center fabric management bows located between the frontattachment assembly 14 and rear attachment assembly 16 running crossbed. For example, the bows 18 help manage the movement of the cover 20to fold during stowage, etc.

The tonneau cover assembly 10 is provided with a cable tensioning systemincluding at least a first tension cable 20 and a second tension cable22. The cables are of the same or different predetermined suitabletype(s) and diameter(s) for providing predetermined tension and tensionrelease forces, dependant on the application. Other tensioning systemsare contemplated depending on the application without departure from thescope of the present invention.

The front attachment assembly 14 includes a pair of front attachmentportions 24 each connected to the respective ends of a first bow 26 thatis a front bulkhead bow. The front attachment blocks 24 provide a nodrill attachment toward the bulkhead of the cargo bed. An attachment arm28 is operably connected to either of the front attachment blocks 24 forattaching the front of the assembly 10, as will be explained in greaterdetail below. A cable attachment feature 30, e.g., with a firstaperture, is formed in either of the front attachment blocks 24 allowingfor mounting locations for the cable tensioning system. The firstaperture preferably is formed on this outward feature of both of thefront attachment blocks 24 for connecting both the first and secondtension cables 20, 22. The attachment arm 28 sets side-to-side and drawsthe attachment arm 28 to the front. Preferably, the attachment arm 28slides on and a fastener, e.g., screw, draws the attachment arm 28 tothe front, in the direction of the cab.

Referring to the Figures generally, and more particularly to FIGS. 3-5,in a preferred embodiment, the attachment arm 28 is generally U-shaped,with two lower depending arms, and is sized to partially fit within anopening 31 formed in the front attachment blocks 24. At least one firstfastener 32, e.g., an attachment bolt, is extendable through at least asecond aperture 34 provided on one of the lower depending arms of theattachment arm 28 and a third aperture 36 formed in a first brace 38. Asecond brace 39 is held, e.g., using adhesive, against the inside of theother arm for mounting to the vehicle. Thus, once the first bow 26, or“front bulkhead” referred to interchangeably herein, is put in place onthe vehicle and then the fastener 32 is tightened, this draws theattachment arm 28 rearward fixing and sealing the front bulkhead 26 tothe bulkhead of the vehicle's bed. In a preferred embodiment, at leastone seal is provided on the front attachment assembly 14 and typicallyseals against the vehicle structure.

The first pair of front attachment blocks are also provided with atleast one first mounting bracket 40, preferably two side-by-side, toconnect to the first bow 26. In a preferred embodiment, the firstmounting brackets 40, 40 slide into the ends of the first bow 26 andfasteners, e.g., bolts, are provided to fix the first bow 26 to thebrackets 40, 40.

Referring to the Figures generally, and more particularly to FIGS. 1-2and 6-7, the rear attachment assembly 16 allows tension to be appliedusing the cable tension system, eliminating the need for side rails toseal the tonneau cover 12 to the vehicle bed. A pair of rear attachmentblocks 42, or “rear tension block” referred to interchangeably herein,are both operably connected to a rear bar 44, cross member 46, and aconnector bar 48, which is a release latch connector bar forming part ofa release latch mechanism indicated generally at 50. The release latchmechanism 50 has a pair of release latches 52 operably connected torespective rear attachment blocks 42.

Both the right and left hand release latches 52 are tied together sothat only one side needs to be operated to open both latches 52. Afourth aperture 54 or a boss is provided on the block of the rearattachment blocks 42 and aligns with a fifth aperture 56 or a bossprovided on the release latches 52 for receiving the connector bar 48.

A second cable attachment feature 60, e.g., with a sixth aperture, isformed in either of the rear attachment blocks 42 allowing for mountinglocations for the cable tensioning system. The sixth aperture preferablyis formed on an outward feature of both of the rear attachment blocks 42for connecting both the first and second tension cables 20, 22.

The pair of rear attachment blocks 42 are also provided with at leastone second mounting bracket 62 to connect to the ends of the crossmember 46. In a preferred embodiment the second mounting brackets 62slide into the ends of the cross member 46 and at least one fastener,e.g., bolts, are provided to fix the cross member 46 to the brackets 62.

Optionally, a pair of rear mounting brackets indicated generally at 64(see FIGS. 1-2) are used.

Referring to the Figures generally, and more particularly to FIG. 8,where the vehicle and bedrails are omitted for clarity, either of thecover management bows 18 are provided with operably profiled/configuredends for preventing undesirable movement on the existing bed rails.Using a flat edge 66, the ends touch off on the vehicle bed railssetting the height of the bows 18/cover 12. The flat edge 66 sitssubstantially flat on top of the bedrail such that the bows 18 cannotdrop into the bed of the vehicle. An operable predetermined step featureformed in the bottom of the ends helps to set side to side positioningagainst the vehicle bed sides. By way of example, a step on the bottomdrops in and sits just inside the bedrail such that the end cannot movetoo far either side.

Referring to FIGS. 1-8 generally, the tonneau cover assembly 10eliminates side rails from the system. In accordance with a preferredembodiment of the present invention, the cable tensioning systemincorporates cables 20, 22 used to create cover 12 tension and seal thecover 12 to the vehicle body. The assembly 10 uses the bedside to locatethe fabric management bows 18, 18 and cover 12 in their side to side andheight orientations. The rear engagement feature, e.g., rear mountingbrackets 64, can be an additional bracket (as shown) or incorporatedinto the bed. The front engagement to the bed feature, e.g., attachmentarms 28, are drawing up on the bulkhead to locate/attach/seal. Theassembly 10 preferably includes an integrated fabric boot cover toprotect the stowed system when rolled and stowed. Depending on theapplication, alternative stowing methods are contemplated withoutdeviation from the present invention. A significant advantage overconventional systems is the use of connected right and left hand latches52, 52 on a tonneau cover.

For reference throughout the Figures the term “front” indicates thevehicle cab direction.

Referring to FIGS. 9-20 generally, there is provided a rear tonneauaccess cover panel assembly shown generally at 100 according to anembodiment of the present invention. The assembly 100 is adapted forattachment, preferably, to mounting points in the cargo bed of thevehicle, which can be any mounting arrangement suitable for durabilityrequirements. The assembly 100 is suitable to meet automotivespecifications and functionality.

The assembly 100 has a rear attachment assembly with a pivotal portionshown generally at 111 for moving between a closed position and a firstopen position to partially uncover the opening into the cargo area. Theassembly 100 includes at least one rear attachment portion 102, at leastone latch mechanism indicated generally at 104 with a release latch 106(or “latch handle assembly”), at least one pivotal member 108 withdetent, e.g., spring loaded detent, on the pivotal portion 111, and atleast one rear mounting mechanism. Any of these features are located oneither side of the assembly 100, preferably, on both sides of theassembly. Most preferably, the right half of the assembly 100 andcorresponding features are substantially mirror image/symmetrical to theleft half of the assembly 100 and corresponding features depicted in thefigures. However, the latch mechanism 104 is such that only one ofeither release latch 106 (or “handle” or “release lever”) need beactuated by an operator for the latch mechanism 104 to be disengaged onboth sides to allow pivotal movement of the pivotal portion 111, as willbe explained in greater detail below.

The assembly 100 also incorporates a front attachment assembly, such aspreviously described front attachment assembly 14, according to anembodiment of the present invention.

The assembly 100 also includes at least one cover 138, e.g., soft cover,operably connected to at least the pivotal portion 111.

Typically, the assembly 100 has at least one mounting bracketarrangement including a rear mounting bracket 101, e.g., L-shapedbracket, that rests on and/or is operably fastened in a U-shapedmounting bracket 103 by at least one fastener. However, alternatively,depending on the application a suitable portion of the assembly 100 isbolted, screwed, welded, riveted, additionally secured with adhesiveand/or epoxy, or combinations thereof or otherwise connected to theU-shaped mounting bracket 103, or other suitably shaped bracket, and/ordirectly to the cargo bed, e.g., side walls of the bed, depending on theapplication. Preferably, at least one attachment portion 102 or“attachment block” is releasably locked into the vehicle bed via therear mounting bracket 101.

The tonneau access cover panel assembly 100 is adaptable andincorporates in combination a cable-type assembly (cover is cabletensioned), tri-fold (e.g., cover is segmented and the assembly folds upgenerally in the direction toward the vehicle cab), roll-up (e.g., theassembly rolls up with the rest of the tonneau, soft panels, hard panels(e.g., two or more smaller hard sections with a living hinge in-linewith pivot points), soft tri-fold, hard or rigid, soft or flexible,manual or electric, hybrid, or any other type of tonneau assembly andcombinations thereof, depending on the application and predeterminedvehicle needs.

The assembly 100 further includes a rear bow 110 and cross member 112.The rear bow 110 is coupled to both pivotal members 108, e.g., by atleast one fastener such as a nut and bolt, etc, or, alternatively,integrally formed with the pivotal members 108. The rear bow 110 is alsooperably coupled to the cover 138 of predetermined tonneau covermaterial. The rear bow 110 is in sealing engagement with the tailgatefor a weather tight seal. The cross member 112 is operably connected toboth attachment portions 102, e.g., slid over a mounting member that isformed on the portions 102 and secured by a plurality of fasteners 109.

The pivotal members 108, rear bow 110, and second cross member 112 aremade of a metal, preferably, aluminum. However, depending on theparticular application, it is also within the scope of the invention tomanufacture the pivotal members 108, rear bow 110, and/or cross member112 of different materials such as steel, composite plastic, or othersuitable impact resistant material to withstand predetermined cyclingrequirements and load without departing from the scope of the invention.

The latch mechanism 104 includes a release latch connector bar 105having a small rod like structure 114, preferably of metal, that isoperably connected, e.g., partially inserted into the connector bar 105,to both ends of the connector bar 105 by at least one fastener 107,e.g., roll pin. Each latch handle assembly 104 includes a hook feature116 that is biased by a detent mechanism 117, such as a spring,preferably, a torsion spring. The hook 116 locks into a respectivecorresponding feature 115 in the assembly, e.g., a recess with anabutting surface formed in the mounting member 101, and/or vehicle cargobed frame. In addition to the connector bar 105, each corresponding rod114 is also operably coupled to the respective release latch 106 handle,attachment portion 102, hook 116 and spring 117. Preferably, the rod 114is inserted into holes in these adjacent parts to keep the partstogether in operational contact. Alternatively, no rod 114 is used andthe connector bar 105 is operably connected to these features. In a mostpreferred embodiment, when the attachment portion 102 is to be coupledto the mounting bracket 101, a forward surface 148 of the attachmentportion 102 enters laterally into an opening 150 formed toward the topof the mounting bracket 101 and is held in the opening 150 by an uppersurface 152 when the hook 116 is locked to the mounting member 101. Whenthe hook 116 is selectively released, the attachment portion 102 isremovable from the opening 150.

Lifting or otherwise manipulating one release latch 106, on either end,results in the rotation of both hooks 116 via the connector bar 105 torelease the hook connection and release some tension. Thus, a user onlyneeds to operate one latch 106; because of the rod 114 (on bothends)/bar 105, both sides are released allowing for selective rotationby the user to the fully open position and any intermediate position(s).To lock the attachment portion 102 into the closed position, the hooks116 are brought back into engagement with the abutting surface 115 onthe mounting bracket 101 and the pivotal portion 111 is rotated toengagement with the tailgate 142.

The pivotal portion's 111 pivot members 108 are pivotally connected tothe attachment portion 102 by a second pin 118 or metal rod and has aspring loaded detent. The combination of a spring 120 backing ananterior block 121 against a posterior surface 108 a of the pivotalmembers 122 locks the pivotal member 108 in up/down positions(open/closed). This also serves to prevent the pivotal members 108/rearbow 110 from bouncing in the open and/or closed positions during vehicletransit. Preferably, the spring 120 is a compression spring. FIG. 13illustrates a closed position, while FIG. 14 illustrates a first openposition. Providing intermediate position(s) is/are contemplated, e.g.,such as that shown in FIG. 15 because of the detent surface(s)/spring120, without departing from the scope of the present invention. FIG. 15is at about 45 degrees, however, greater or lesser degrees arecontemplated.

The rear bow 110 is operably adapted to be in sealing engagement withthe tailgate shown generally at 142 (FIG. 13).

According to an embodiment of the present invention, the rear bow 110includes an operably shaped channel 124 to slidably receive and retain aseal 126. Most preferably, the seal 126 is a bulb seal having at leastone bulb. Although an exemplary channel 124 is shown, it is understoodthat the channel 124 can have any shape suitable for receiving anopposing connecting feature of the seal 126. The seal 126 is slid intothe channel 124 and operably held in place by friction and/or at leastone fastener and/or at least one other suitable feature to prevent theseal 126 from leaving the channel 124. Preferably, the channel 124 isgenerally located on the underside of the rear bow 110. Most preferably,channel 124/bulb attaches toward the leading edge of the rear bow 110.The bulb seal 126 goes against a predetermined portion of the tailgatefor a weather resistant seal. The spring loaded detent 120/121/108pushes the pivotal members 108/rear bow 110 in the direction toward thetailgate and therefore pushes the seal 126 against the tailgate.

Generally, the seal 126 is an extruded material of polypropylene,thermoplastic elastomer, soft TPE (Thermoplastic Elastomer), rigid PVC,flexible PVC, PVC vinyl, PVC rubber, ABS, a structural ABS(Acrylonitrile Butadiene Styrene), polypropylene, or other plasticmaterial or other suitable material and combinations thereof suitablefor providing a structural portion to remain in the channel 124 andadditionally a resilient seal portion, e.g., bulb.

The rear bow 110 also includes an operably shaped second channel 128 toreceive a mounting portion of the tonneau cover. Preferably, themounting portion is an extrusion 129 is sewn to the cover and slid intothe second channel 128. The extrusion/cover 128 is held in place byfriction and/or at least one fastener and/or at least one other suitablefeature to prevent the cover from leaving the second channel 128. Mostpreferably, no fasteners are used to connect the cover to the channelwhich is a significant benefit. In one embodiment the channel 128 isgenerally located on the underside of the rear bow 110 toward a leadingedge when in the closed position. This allows the cover to wrap up andaround the bow edge and back so that the frame of the assembly 100 isnot visible. Preferably, the channel 128 is located on the leading edgeof the rear bow 110 when in the closed position. The mounting portion isa predetermined shape received in the channel 128 in the rear bow 110.Other suitable arrangements, P-welts, C-shaped channels, can be used tocouple the cover 138 to a bow (such as in known manners described inU.S. Pat. No. 6,322,129 B2 incorporated herein by reference).

According to an embodiment of the present invention, in operation, theuser flips the pivotal portion 111 rearward to a first open position togain partial access to the cargo bed structure. When a larger openinginto the structure is desired, the user rotates the release latch 106 ina first direction which disengages the hook 116 from the mountingbracket 101 allowing the pivotal portion 111 with the cover 138 attachedto be rolled, or otherwise suitably articulated, as far back toward thefront attachment assembly 14 as desired. Rolling the unit all the way toadjacent the front attachment assembly 14 provides a fully uncoveredopening into the cargo bed.

In a preferred embodiment, only the mounting bracket arrangement withthe rear mounting bracket 101 and mounting bracket 103 stays in theaffixed position after unlatching the hooks 116 allowing selectiverotation of the rest of the assembly to a fully open position, e.g.,positioned adjacent the cab for greatest access into the cargo bed. In apreferred embodiment, once the hooks 116 are unlatched, the cover withthe attached pivotal portion 111 is able to be rolled up and stowedtoward the front attachment assembly 14. Straps can be used to keep therolled assembly 100 in the fully open position and/or any intermediateopen position(s).

According to the present invention, there are predetermined desiredpositions of the assembly 100 with predetermined amounts of access intothe cargo bed of the vehicle indicated generally at 130. The assembly100, preferably the rear bow 110, is in sealing engagement against thetailgate 142 in a closed position. When in the first open position, thepivotal portion 111 has been pivoted back to create an opening ofpredetermined width, e.g., not more than 6 inch opening. In one or morepredetermined deployed position(s) the assembly 100 is provided incombination with a tri-fold cover or any other type of tonneau coverassembly, and when deployed, an opening of predetermined width, e.g.,quarter, half, and/or full top access into the cargo bed. These examplesare exemplary and not limiting.

Generally, when the assembly 100 is in the first open position the widthof the opening into the bed is at least 3 inches, typically 3-10 inches,preferably 4-8 inches, most preferably about 6 inches.

In one embodiment, another safety advantage option of the presentinvention is that the assembly 100 cannot be operated unless thetailgate is unlatched and/or unlocked.

In one preferred embodiment, a cable attachment feature 134 is providedon the attachment portion 102 for attaching cable(s) 135 for a cabletonneau cover assembly. Preferably, the cable 135 is not a hardattachment to the vehicle to help manage the cable/cover/sealing. Thecable 135 eliminates Velcro hook and loop for sealing, which is asignificant benefit over conventional systems. Rather, the cable 135holds the cover 138 taut as desired along at least the outboard sides ofthe cover 138. The cable 135 is also attached to at least the frontattachment assembly 14, e.g., to the attachment block 24. Otherattachment point(s) are contemplated depending on the applicationwithout departure from the scope of the present invention. Othercable-type arrangements are contemplated depending on the applicationwithout departure from the scope of the present invention. According toan embodiment of the present invention, at least one weather resistantseal is provided on the cover, e.g., sewn and/or adhered, near the sidesand/or rear of the cover 138.

Referring more particularly to FIG. 19, the cable is located within acable pocket 136, where the cable pocket 136 is sewn and/or adheredalong the outer edge of the cover 138.

Preferably, a plurality of pockets 140 are provided to hold both ends ofcenter management bow(s) 144. There are provided at least one,preferably at least two, most preferably at least three, centermanagement bows 144. The bows 144 set the height and eliminate aluminumrails and attachment features, which such rails are conventionallyrequired. The center management bows 144 also assist with covermanagement. The pockets 140 have a predetermined suitable height andwidth depending on the application. The pockets 140 also set thedistance between each center management bow 144. The center managementbows 144 run cross-car. The cable pocket 136 preferably runs pastoutwardly from the pockets 140 for center management bows 144.

When the top cover is fabric or other flexible material these pockets140, most preferably, of molded acrylonitrile butadiene styrene (ABS),having predetermined suitable thickness, are sewn and/or adhered to atleast the cover. The pockets 140 are on the underside surface of thecover 138, thus not visible when the cover 138 is in the closedposition. Each end of the center management bows 144 are slid into anopening 146 in a respective pocket 136. Preferably, the pockets 140 reston existing original manufacturer bed features/rails and sets the heightand cross-car relative to the bed. The pockets 140 sets the height andare thin enough to sew to the cover material. The pockets 140 set thedistance between the bows 144 and, in combination with the bows 144,help with moving the assembly to a fully open position and anyintermediate open position(s), e.g., to help with rolling thecover/assembly. The pockets 140 also eliminate the addition of aluminumrails for the cover and eliminate the tongue and loop for cover sealing,which are significant advantages.

While a cable-type tonneau cover assembly is depicted in the figures,the assembly 100 can be used in combination with any type of tonneaucover assembly without departing from the scope of the presentinvention.

Referring now to FIGS. 21-33, there is depicted a tonneau cover accesspanel assembly (or “assembly”) shown generally at 200. The assembly 200is adapted for attachment to a plurality of pre-drilled mounting pointsprovided on the cargo bed, shown generally at 202 of the vehicle 204,which can be any mounting arrangement suitable for durabilityrequirements. Alternatively, installation includes first drillingmounting points in the cargo bed. The assembly 200 is suitable to meetpredetermined automotive specifications and functionality and/or anypredetermined after-market requirements. The assembly 200 has at leastone tensioning system, shown generally at 206, e.g., a cable-typesystem, and at least one cover 208 that is generally rollable forstorage. However, it is understood that alternative tensioning systemsand/or alternative covers/storage methods are contemplated depending onthe particular applications without departure from the scope of thepresent invention. The assembly 200 also has a latching mechanism,indicated generally at 210, that includes at least one release lever,shown generally at 211, including at least one handle 212 connected to aconnecting bar 214 such that the handle 212 can be pulled generallyforward (in the direction toward the vehicle tailgate 216) to release alatch 218 from a mounting bracket 220 connected to the vehicle bed 202.The location and pull direction of the handle 212 is more convenient andeasier to handle for an operator because there is less interference withthe cover 208 than if having to turn the handle in a more upwarddirection, for example, where there would be limited space due to thecover 208 being more in the way above.

The assembly 200 has a rear attachment assembly shown generally at 222that engages the tailgate 216 to close off a top opening into thevehicle bed 202. A pivotal portion shown generally at 224 of the rearattachment assembly 222 rotates between a closed position (FIG. 30) anda first open position (FIG. 31) or “flipped back” to partially uncoverthe top opening into the cargo bed 202. In an embodiment of the presentinvention, the pivotal portion 224 has detent, e.g., spring loadeddetent, (e.g., generally as described previously). At least one rearattachment portion 226 of the rear attachment assembly 222 isselectively connected to the mounting bracket 220. When the rearattachment portion 226 is not connected to the mounting bracket 220, therear attachment assembly 222 can be rolled with the cover 208 toward thecab (FIG. 32) and secured in the fully open position (FIG. 33), whichuncovers the top opening into the cargo bed 202. However, when the rearattachment portion 226 is connected to the bracket 220, the rearattachment assembly 222 and cover 208 cannot be rolled; rather, only thepivotal portion 224 can be moved (between the closed and flipped backpositions).

To selectively connect the rear attachment portion 226 to the mountingbracket 220 the operator aligns one end 228 of the attachment portion226 within a first recess 230 formed in the mounting bracket 220 (FIG.24). FIG. 24 illustrates the latch 218 in an unlatched position. Thelatch mechanism 210 is then moved to engage the latch 218 with themounting bracket 220 (FIG. 25). In particular, a bottom surface of theattachment portion 226 is brought down to adjacent a top surface of themounting bracket 220 and the latch 218, e.g., which is generallyhook-shaped, is rotated to engage a second recess 232 with a top lipformed in the mounting bracket 220. FIG. 25 illustrates the latch 218 ina latched position, thereby connecting the rear attachment portion 226to the mounting bracket 220. When desired, the operator pulls the handle212 to unlatch the latch 218 again. The handle 212 rotates the connectorrod 214 connected thereto, which connector rod 214 is also connected tothe latch 218 and rear attachment portion 226. Thus, pulling the handle212, e.g., in the direction generally toward the tailgate, causes theconnector rod 214 and latch 218 to rotate in a first direction tounlatch the latch 218 from the mounting portion 220. In one embodiment,pushing the handle 212, e.g., in a direction generally away from thetailgate, causes the connector rod 214 and latch 218 to rotate in asecond direction to latch the latch 218 to the mounting portion 220.Alternatively, the latch 218 is operably biased toward the seconddirection, and pulling the handle 212 overcomes the bias force to rotatethe latch 218 to the unlatched position.

Preferably, two handles 212 are connected to the connector bar 214, and,since pulling either handle 212 causes the bar 214 to rotate, pullingjust one handle 212 causes both latches 218 to unlatch from therespective mounting brackets 220.

At least one fastener 234 connects the mounting bracket 220 to at leastone mounting point 236, e.g., aperture, located toward the upper innerside of the vehicle bed 202.

The pivotal portion 224 is rotatably connected to the rear attachmentportion 226 by two pivotal members 250. The pivotal portion 224 also hasa rear bow shown generally at 238 with at least one channel 240 forholding at least one retainer 242 connected to the cover 208, e.g.,sewn, to secure the cover 208 to the pivotal portion 224. Preferably, atleast one second channel 248 is formed on the sides of rear cornersegments 254 of the pivotal portion 224 to receive a respective retainerconnected to the cover 208 for more secure, taut connection of the cover208 to the assembly 200. A seal 243 is connected to another channelformed in the rear bow 238 for sealing with the tailgate 216 when in theclosed position. Preferably, the rear bow 238 is an aluminum extrusion.

The rear attachment portion 226 is also connected to a cross member 244.The connector bar 214 runs within or directly under the cross member244. Most preferably, the cross member 244 is a generally U-shapedmember to help protect the latching mechanism features, while at thesame time reducing the amount of material needed. At least one cutout246 is located on the cross member 244 for placement of the respectivehandle 212. Preferably, the cross member 244 is an aluminum extrusion.

The assembly 200 also includes a front attachment assembly showngenerally at 252 including a front bow 256 connected to front railcorner attachment portions 258. The front attachment portions 258 reston the top edge of the side of the vehicle bed and are also connected tothe bulkhead of the cargo bed 202. At least one fastener 260 connectseach front attachment portion 258 to a respective mounting point 262,e.g., aperture, located toward the upper front end of the vehicle bed202. Preferably, the fastener 260 is a spin washer with a screw. In analternative embodiment, the front attachment assembly 252 is adapted tobe a no drill attachment, as described previously.

Preferably, the front bow 256 is an aluminum extrusion.

The front bow 256 is connected to the front edge of the cover 208. Aseal is also preferably provided for sealing engagement with thebulkhead.

The front bow 256 is shaped, e.g., curved or bowed, when desired tocorrespond with the shape of the bulkhead depending on the particularapplication.

A plurality of pockets 264 are provided to hold both ends of a pluralitycover management bows 266, respectively. The bows 266 are connectedwithin each pocket 264. Most preferably, at least one fastener 268,e.g., screw, connects the pocket 264 to the bow 266. The pockets 264 arealso connected to the cover 208, e.g., sewn and/or adhered in at leastone location of the pocket to the cover (exemplary sew lines 270 todepict locations for the sewing of the pockets 264 to the cover 208 areshown in FIG. 28A). The bows 266 are thereby connected to the cover 208by way of the pockets 264. However, additional attachments to the cover208 for each bow 266 are contemplated without departure from the scopeof the present invention. The pockets 264 rest on the top side edges ofthe cargo bed 202 (best shown in FIG. 21).

Preferably, there are at least three bows 264. Typically, the pocketsare acrylonitrile butadiene styrene (ABS). Preferably, the pockets 264are vacuum formed polycarbonate.

The cable system 206 of the assembly 200 includes at least one cable272. The cable 272 is connected to the rear attachment portion 226 andthe front attachment portion 258 and runs within a cover pocket 274along the side of the cover 208, which is preferably a sewn and/oradhered pocket 274 formed in the cover 208. The pocket 274 is locatedgenerally outboard from a seal 276 connected to the underside of thecover for sealing engagement with the top edge of the cargo bed 202 sidewalls.

Thus, the cable system runs fore and aft. However, the tensioning systemadditionally runs inboard as well. The cable, preferably, at least oneother cable 278 is connected to the front attachment portion 258 andextends along the inside of the front bow 256 across the bulkhead. In amost preferred embodiment, the cable 278 is connected to a spring 280,which spring 280 is connected to at least one fastener 282 or bracketlocated about half way across the bulkhead. On the other side of thefastener 282, or via an additional fastener connected to the bulkhead,another spring is provided that is connected to another cable, whichcable is connected to the other front attachment portion. FIG. 27illustrates the left hand cable 278 and spring 278 connected to thefastener 282, which is connected to the bulkhead toward the front of thecargo bed 202. It is understood that the right side would besubstantially a mirror-image to the left side. Thus, the cable systemruns fore and aft, and additionally has cable tensioning along the frontof the assembly 200. The springs 278 improve cable tensioning.

Alternatively, the cable 272 is connected to the rear attachment portion226 at one end, is channeled through the front attachment portion 258,and is connected at the other end to the spring 280.

Generally, the seals of the assembly 200 are an extruded material ofpolypropylene, thermoplastic elastomer, soft TPE (ThermoplasticElastomer), rigid PVC, flexible PVC, PVC vinyl, PVC rubber, ABS, astructural ABS (Acrylonitrile Butadiene Styrene), polypropylene, orother plastic material or other suitable material and combinationsthereof.

Generally, when the pivotal portion 224 is in the first open position,the width of the opening into the bed is at least 3 inches, typically3-10 inches, preferably 4-8 inches, most preferably about 6 inches. Whenthe assembly 200 is in the open position, straps 284 can be used to keepthe cover 208 rolled.

Most preferably, the right half of the assembly 200 and correspondingfeatures are substantially mirror image/symmetrical to the left half ofthe assembly 200 and corresponding features depicted in the figures.

In one embodiment, another safety advantage option of the presentinvention is that the assembly cannot be operated unless the tailgate isunlatched and/or unlocked.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the essence of the inventionare intended to be within the scope of the invention. Such variationsare not to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. A tonneau cover assembly adapted for a vehicle,comprising: at least one rear attachment assembly adapted for operablycoupling to the vehicle adjacent a top cargo bed opening of the vehicle,said at least one rear attachment assembly including a pivotal portionoperably coupled to a cover, wherein pivoting the pivotal portion in afirst direction moves the cover to a first position to close off the topcargo bed opening of the vehicle and pivoting the pivotal portion in asecond direction to a second position partially uncovers the top cargobed opening of the vehicle; at least one tensioning system connected tothe cover and connected to at least the at least one rear attachmentassembly to tension the cover; at least one latching mechanism includingat least one release member adapted to selectively unlatch the at leastone rear attachment assembly from the vehicle, wherein unlatching the atleast one release member allows selective further uncovering of the topcargo bed opening of the vehicle.
 2. The tonneau cover assembly of claim1, wherein the at least one tensioning system is a cable arrangementincluding a pair of cables coupled to respective sides of the cover andoperably connected to opposite ends of the at least one rear attachmentassembly.
 3. The tonneau cover assembly of claim 1, wherein the at leastone tensioning system is operably connected to a front attachmentassembly adjacent a front of the top cargo bed opening of the vehicle.4. The tonneau cover assembly of claim 2, wherein the cable on bothsides of the cover additionally extend inboard to operably connect to afront attachment assembly for further tensioning adjacent a front of thetop cargo bed opening of the vehicle.
 5. The tonneau cover assembly ofclaim 4, further comprising at least one pair of springs connected to atleast one fastener on the front attachment assembly, wherein each cablethat runs inboard is operably connected to a respective spring of saidat least one pair of springs for further cable tensioning.
 6. Thetonneau cover assembly of claim 1, wherein the cover is rollable to anopen/stowed position and securable to a front attachment assembly. 7.The tonneau cover assembly of claim 1, further comprising at least oneseal along at least both sides of the cover in a fore and aft directionadapted to provide a weather resistant seal against the vehicle.
 8. Thetonneau cover assembly of claim 1, further comprising at least one sealoperably coupled to the rear attachment assembly and/or a frontattachment assembly adapted to provide a weather resistant seal againstthe vehicle.
 9. The tonneau cover assembly of claim 1, furthercomprising a plurality of cover management bows operably coupled to thecover running cross-vehicle, said plurality of cover management bowsadapted to operably selectively engage with the vehicle adjacent the topcargo bed opening.
 10. The tonneau cover assembly of claim 9, furthercomprising a plurality of pockets operably connected to opposing sidesof the cover, wherein each end of the plurality of cover management bowsis located within a respective pocket.
 11. The tonneau cover assembly ofclaim 10, wherein the plurality of pockets is adapted to operably reston sidewalls of the vehicle adjacent the top cargo bed opening of thevehicle.
 12. The tonneau cover assembly of claim 1, wherein the secondposition creates a gap of about 3 to 10 inches for limited access intothe top cargo bed opening of the vehicle.
 13. The tonneau cover assemblyof claim 1, further comprising a pair of mounting brackets, eachmounting bracket adapted to be connected to the vehicle adjacent the topcargo bed opening of the vehicle by at least one fastener.
 14. Thetonneau cover assembly of claim 13, wherein the at least one releasemember includes at least one handle operably connected to a connectingbar, wherein pulling the at least one handle causes rotation of theconnecting bar to unlatch a respective hook from each mounting bracketthereby unlatching the latching mechanism.
 15. A tonneau cover assemblyadapted for a vehicle cargo bed structure, comprising: a cover operablyadapted for sealing a top opening of the vehicle when said tonneau coverassembly is in a closed position, wherein the cover is moveable betweenat least the closed position, a partially open position and a fully openposition, said cover including fabric material; at least one tensioningsystem operably coupled to the cover to keep the cover under tensionwhen in the closed position for sealing; a pair of mounting brackets,wherein the mounting brackets are adapted to be connected to oppositesidewalls of the vehicle adjacent the top opening of the vehicle with atleast one fastener; a first recess formed in the pair of mountingbrackets; a second recess formed in the pair of mounting brackets; apair of rear attachment portions operably connected at both ends of across member, said pair of rear attachment portions including an endfeature operable to selectively fit within the first recess; a pair ofcutouts formed in the cross member; at least one release memberincluding a pair of handles, each rotatable within the pair of cutouts,respectively, and, each operably connected to a connecting bar; a pairof release latches operably connected toward both ends of the connectingbar and rotatable with the connecting bar, wherein moving either of thehandles in a first direction causes rotation of the connecting bar torotate both release latches from the second recess of the mountingbrackets thereby unlatching the pair of rear attachment portions fromthe mounting brackets in order to allow the cover to be selectivelymoved to the fully open position when desired, and wherein moving eitherof the handles in a second direction causes rotation of the connectingbar to rotate both release latches into the second recess of themounting brackets thereby latching the pair of rear attachment portionsto the mounting brackets to allow the cover to be selectively movedbetween the partially open and closed positions when desired; and apivotal portion operably coupled to the cover and to the pair of rearattachment portions, wherein pivoting the pivotal portion moves thecover between the closed position and the partially open position topartially uncover the top opening of the vehicle.
 16. The tonneau coverassembly of claim 15, further comprising a pair of front rail cornerattachments operably connected to both ends of a front bow member,wherein the cover and the at least one tensioning system are operablycoupled to at least the pair of front rail corner attachments.
 17. Thetonneau cover assembly of claim 16, wherein the at least one tensioningsystem comprises at least two cables each connected to a respectivespring that is operably connected to the front bow member, wherein oneend of each cable is connected to one of each of the pair of rearattachment portions, each cable extends through the respective frontrail corner attachment, and the other end of each cable is connected tothe respective spring.
 18. The tonneau cover assembly of claim 15,further comprising at least one pair of seals, wherein the seals areoperably connected to the underneath surface of the cover along bothsides of the cover in the fore and aft direction adapted to seal againstthe vehicle's sidewalls.
 19. The tonneau cover assembly of claim 15,further comprising at least one fabric management bow connected atopposite ends to a pocket, wherein each pocket is connected to thecover, and, wherein each pocket is adapted to be selectively operablylocated on the fore and aft sidewalls of the vehicle adjacent the topopening of the vehicle.
 20. A tonneau cover assembly adapted for avehicle that has a cargo bed structure with a top opening and atailgate, comprising: a cover moveable between at least a closedposition to cover the top opening, a partially open position and a fullyopen position; at least one tensioning system that is a cable systemoperable to tension the cover; at least one fabric management bowconnected to the cover; a front attachment assembly operably connectedto a front of the cover; a plurality of mounting brackets connected to aplurality of apertures located toward the upper sidewalls of the vehicleby a plurality of fasteners; a first recess formed in the plurality ofmounting brackets; a second recess formed in the plurality of mountingbrackets; a pair of rear attachment portions operably connected at bothends of a cross member, said pair of rear attachment portions includingan end feature operable to selectively fit within the first recess; apair of cutouts formed in the cross member; at least one release leverincluding a pair of handles, each rotatable within the pair of cutouts,respectively, and, each operably connected to a connecting bar; a pairof release latches operably connected toward both ends of the connectingbar and rotatable with the connecting bar, wherein moving either of thehandles toward a first direction causes rotation of the connecting barto rotate both release latches from the second recess of the pluralityof mounting brackets thereby unlatching the pair of rear attachmentportions from the plurality of mounting brackets in order to allow thecover to be selectively moved to the fully open position when desired,and wherein moving either of the handles toward a second directioncauses rotation of the connecting bar to rotate both release latchesinto the second recess of the plurality of mounting brackets therebylatching the pair of rear attachment portions to the plurality ofmounting brackets to allow the cover to be selectively moved between thepartially open and closed positions when desired; and a pivotal portionoperably coupled to a rear of the cover and to the pair of rearattachment portions, wherein pivoting the pivotal portion moves thecover between the closed position adapted for sealing engagement againstthe tailgate and the partially open position adapted to partiallyuncover the opening of the vehicle.